Design of Plunger Screws Ofinjection Molding Machine

DESIGN OF PLUNGER SCREWS OF
INJECTION MOLDING MACHINE

PRESENTED BY-
AVIJIT KUMAR
SPG0618003
Vertical & Horizontal Plunger Type Injection Molding Machine

INJECTION MOLDING PROCESS
Solid Wide neck, Flat Product is made

like bucket, cabinets, Automobile &
Industrial parts etc…. by injecting
molten thermoplastic material in to a
closed mould which is relatively cool.
TYPES OF INJECTION MOLDING MACHINE
 Hand Injection Moulding M/C
 Plunger type Injection Moulding

M/C
 Reciprocating Screw Type

Injection Moulding M/C
PLUNGER TYPE INJECTION
MOLDING MACHINE
Vertical & Horizontal Plunger Type Injection Molding Machine

THE PLUNGER SCREWS
 The feeding zone
 The compressing (or transition) zone
 The metering zone
MACHINE COMPONENTS
THE INJECTION PROCESS
 Plasticises the material by reciprocating Screw.
 Injects the molten material to a closed mould

via a channel system of gates and runners.
 Cools the Mold.
 Refills the material for the next cycle.
 Ejects the Product.
 Closes the Mold for further cycle.

Screw Used in Injection Molding Machines
The screw has three zones with a ring-plunger assembly. The Feed Zone, where
the plastic first enters the screw and is conveyed along a constant root
diameter; the Transition Zone, where the plastic is conveyed, compressed and
melted along a root diameter that increases with a constant taper; and the
Metering Zone, where the melting of the plastic is completed and the melt is
conveyed forward along a constant root diameter reaching a temperature and
viscosity to form parts.
L/D RATIO
 The L/D ratio is the ratio of the flighted length
(Effective Length) of the screw to its outside
diameter.
 Most injection screws use a 20:1 L/D ratio. But it

may range from 18:1 to 24:1
 In the case of Thermoset it may range from 12:1

to 16:1.
High L/D Ratio results the following ….
 More shear heat can be uniformly
generated in the plastic without
degradation;
 Greater the opportunity for mixing, resulting

in a better homogeneity of the melt.
 Greater the residence time of the plastic in

the barrel possibly permitting faster cycles
of larger shots.
COMPRESSION RATIO (CR)
 The ratio of the first flight depth of feed zone to
the last flight depth of meter zone ,
Or,
 First Channel Volume of feed zone to last channel
volume of metering zone,
 Typically ranges from 1.5:1 to 4.5:1 for most
thermoplastic materials.
 Most injection screws classified as general purpose
have a compression ratio of 2.5:1 to 3.0:1.
 Thermo set screws have a 1:1 ratio.
Higher the CR results the following ….
 Greater shear heat imparted to the resin
 Greater heat uniformity of the melt
 High Potential for creating stresses in

some resins
 High energy consumption

Back Pressure (Kg/Cm2 or bar)
Back pressure is the amount of pressure
exerted by the material ahead of the screw,
as the screw is pushed back in preparation
for the next shot.
Effect of Back Pressure

 More Homogeneous Mix
 Proper Melting
 More compact
 Sometime leads degradation
Injection Speed (cm/Sec)
The injection speed is the forward speed of

the screw during its injection operation per
unit time.
Effect of Injection Speed

 Easy Injection of Material
 Avoid Short-Shot
 Some times leads more orientation & burn
marks
Screw Rotation Speed
The screw rotation speed (RPM) is the rate at which
the plasticizing screw rotates.
The faster the screw rotation result the following ..
 Faster the material is compressed by the screw

flights
 Increasing the amount of shear heating
 Low residence time, some less melting

Cushion
The cushion is the difference in the final forward position of
the screw and its maximum allowable forward position.
 More Cushion results more residence time, some time
degrades.
 If the screw were allowed to travel its full stroke and stop
mechanically against the nozzle, the cushion would be
zero.
 With zero Cushion no hold on works.
 Typically a cushion of 3 to 6 mm is used.
During Refilling
During Injection
Advantages of Injection Moulding Process
 Parts can be produced at high production rates.
 Large volume production is possible.
 Relatively low labour cost per unit is obtainable.
 Process is highly susceptible to automation.
 Parts require little or no finishing.
 Many different surfaces, colours, and finishes are
available.
 Good decoration is possible.
 For many shapes this process is the most economical way
to fabricate.
 Process permits the manufacture of very small parts
which are almost impossible to fabricate in quantities by
other methods.
Limitations of Injection Moulding
 Intense industry competition often results in low profit
margins.
 Mould costs are high.
 Moulding machinery and auxiliary equipment costs are
high.
 Lack of knowledge about the fundamentals of the process
causes problems.
 Lack of knowledge about the long term properties of the
materials may result in long-term failures.
Machine operation sequence
The mould closes and the screw begins moving forward
for injection.
The cavity fills as the reciprocating screw moves forward, as

a plunger.
The cavity is packed as the screw continuously moves forward.
The cavity cools as the gate freezes off and the screw begins to
retract to plasticize material for the next shot.
The mold opens for part ejection
The mould closes and the next cycle begins

Injection Moulded Items
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Design of Plunger Screws Ofinjection Molding Machine

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Design of Plunger Screws Ofinjection Molding Machine

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DESIGN OF PLUNGER SCREWS OF

INJECTION MOLDING MACHINE

Vertical & Horizontal Plunger Type Injection Molding Machine

Solid Wide neck, Flat Product is made

 Hand Injection Moulding M/C

 Plunger type Injection Moulding

 Reciprocating Screw Type

Vertical & Horizontal Plunger Type Injection Molding Machine

 Injects the molten material to a closed mould

 Cools the Mold.

 Refills the material for the next cycle.

 Ejects the Product.

 Closes the Mold for further cycle.

 Most injection screws use a 20:1 L/D ratio. But it

 In the case of Thermoset it may range from 12:1

 Greater the opportunity for mixing, resulting

 Greater the residence time of the plastic in

 Greater shear heat imparted to the resin

 Greater heat uniformity of the melt

 High Potential for creating stresses in

 High energy consumption

Effect of Back Pressure

The injection speed is the forward speed of

Effect of Injection Speed

The faster the screw rotation result the following ..

 Faster the material is compressed by the screw

 Increasing the amount of shear heating

 Low residence time, some less melting

The cavity fills as the reciprocating screw moves forward, as

The mould closes and the next cycle begins

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